Sofa Kit

ABSTRACT

This invention concerns a sofa which solves the problems of the prior art by providing a sofa that can easily be assembled or disassembled by the end consumer at home. The disassembled sofa can be stored in 3 flat boxes. Storage in the flat boxes not only helps the warehouse to store the sofa, but when the end user has purchased the sofa it is easier in such flat boxes to transport it to the location where it will be assembled. The way this invention accomplishes these results is as follows: The parts of the sofa can be broken down into three boxes. Chaise sections can be assembled by placing the seat back flat on the ground and placing the seat frame/arm upright on top of the seat back. A metal threaded rod is used to connect the seat frame and the seat back. A metal nut is used to secure the seat frame to the back using a wrench that comes provided in the package of the kit. The legs are then twisted onto the bottom of the seat frame.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patent application Ser. No. 12/383,905. Applicant claims the benefit of the Mar. 30, 2009 filing date of that application pursuant to 35 U.S.C. §120 and 37 CFR §1.78.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

This invention was not made using federally sponsored research and development.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

None.

REFERENCE TO A SEQUENCE LISTING

There is no sequence listing in this application.

BACKGROUND OF THE INVENTION

This invention relates to the field of furniture and more particularly to the packaging of sofa kits. Sofas have long been known in the furniture making arts but the traditional sofa design with a one piece frame is not susceptible to easy assembly and disassembly. It is also not easy to package such a sofa in a flat box for storage at the seller's warehouse.

BRIEF SUMMARY OF THE INVENTION

This invention concerns a sofa which solves the problems of the prior art by providing a sofa that can easily be assembled or disassembled by the end consumer at home.

The disassembled sofa can be stored in a flat box. Storage in the flat box not only helps the warehouse to store the sofa, but when the end user has purchased the sofa it is easier in such a flat box to transport it to the location where it will be assembled.

The way this invention accomplishes these results is as follows: The parts of the sofa can be broken down into three boxes. Chaise sections can be assembled by placing the seat back flat on the ground and placing the seat frame/arm upright on top of the seat back. A metal threaded rod is used to connect the seat frame and the seat back. A metal nut is used to secure the seat frame to the back using a wrench that comes provided in the package of the kit. The legs are then twisted onto the bottom of the seat frame.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a fully exploded diagram of the first portion of the kit.

FIG. 2 shows the first step in the assembly of the first portion.

FIG. 3 shows the second step in the assembly of the first portion.

FIG. 4 shows the third step in the assembly of the first portion.

FIG. 5 shows the fourth step in the assembly of the first portion.

FIG. 6 shows the final step in the assembly of the first portion.

FIG. 7 shows a floor plan of how the three portions are situated in a room.

FIG. 8 shows a fully exploded diagram of the parts of the second portion of the sofa kit.

FIG. 9 shows the first assembly step of the second portion.

FIG. 10 shows the second assembly step of the second portion.

FIG. 11 shows the third assembly step of the second portion.

FIG. 12 shows the fourth assembly step of the second portion.

FIG. 13 shows the fifth assembly step of the second portion.

FIG. 14 shows a fully exploded diagram of the third portion of the sofa kit.

FIG. 15 shows a cutaway view of the interior of the ottoman.

FIG. 16 shows the first step of the assembly of the third portion.

FIG. 17 shows the third portion with the legs attached.

FIG. 18 shows the final step of assembling the third portion.

DETAILED DESCRIPTION OF THE INVENTION

This invention concerns a sofa which solves the problems of the prior art by providing a sofa that can easily be assembled or disassembled by the end consumer at home.

The disassembled sofa can be stored in a flat box. Storage in the flat box not only helps the warehouse to store the sofa, but when the end user has purchased the sofa it is easier in such a flat box to transport it to the location where it will be assembled.

The way this invention accomplishes these results is as follows: The parts of the sofa can be broken down into three boxes. Chaise sections can be assembled by placing the seat back flat on the ground and placing the seat frame/arm upright on top of the seat back. A metal threaded rod is used to connect the seat frame and the seat back. A metal nut is used to secure the seat frame to the back using a wrench that comes provided in the package of the kit. The legs are then twisted onto the bottom of the seat frame.

Turning now to FIG. 1, the parts found in the first box are shown disassembled. The first box contains four metal threaded rods (1), four nuts (2), four lock washers (3), four washers (4), a wrench (5), four feet (G)(of which one is shown over-sized in FIG. 1 so detail can be seen), a first portion base (A), a first portion main back (B), and a first portion secondary back (C). Turning now to FIG. 2, two of the metal threaded rods (1) are being used to attach the first portion main back (B) to the first portion base (A) by connecting to each of the metal threaded rods (1) on the far side of the first portion base (A) in the following order: a washer (4), a lock washer (3), and a nut (2) using the wrench (5). Turning now to FIG. 3, two of the metal threaded rods (1) are being used to attach the first portion secondary back (C) to the first portion base (A) by connecting to each of the metal threaded rods (1) on the far side of the first portion base (A) in the following order: a washer (4), a lock washer (3), and a nut (2) using the wrench (5). Turning now to FIG. 4, the feet (G) are screwed into the four bottom corners of the first portion base (A). FIG. 5 shows the first portion after assembly and FIG. 6 shows the assembled first portion after cushions are added. The wrench (5) may be omitted from this box if it is contained in the second box.

The first portion, the second portion and the third portion will eventually be arranged in the pattern seen from above at FIG. 7, showing the arrangement of a chaise lounge, a sofa and an ottoman.

Turning now to FIG. 8, the parts found in the second box are shown disassembled. The second box contains five metal threaded rods (1), five nuts (2), five lock washers (3), five washers (4), a wrench (5), four feet (G)(of which one is shown over-sized in FIG. 8 so detail can be seen), a second portion base (D), a second portion main back (F), and a second portion secondary back (E). Turning now to FIG. 9, two of the metal threaded rods (1) are being used to attach the second portion secondary back (E) to the second portion base (D) by connecting to each of the metal threaded rods (1) on the far side of the second portion base (D) in the following order: a washer (4), a lock washer (3), and a nut (2) using the wrench (5). Turning now to FIG. 10, three of the metal threaded rods (1) are being used to attach the second portion main back (F) to the second portion base (D) by connecting to each of the metal threaded rods (1) on the far side of the second portion base (D) in the following order: a washer (4), a lock washer (3), and a nut (2) using the wrench (5). Turning now to FIG. 11, feet (G) are being screwed into the four bottom corners of the second portion base (D). FIG. 12 shows the second portion assembled and FIG. 13 shows the second portion after cushions have been added. The wrench (5) may be omitted from the second box if it is contained in the first box.

Turning now to FIG. 14, the third portion is shown in a fully exploded diagram to have a third portion base (H), and four feet (G). FIG. 15 is a cutaway view showing the frame of wood or other suitable substance that the fabric or other upholstery is mounted on. Turning now to FIG. 16, the feet (G) are being screwed onto the four bottom corners of the third portion base (H). FIG. 17 shows the third portion assembled and FIG. 18 shows the third portion after a cushion has been added. The third portion is of course shipped, stored, and sold in the third box.

The parts of this sofa kit can thus be fit into three boxes for easy shipping, storage, and sale and yet they can easily be assembled at home by the end user. The attachment means shown on the feet (G) in the drawing sheets comprises a threaded metal cylindrical extension which can be screwed into a corresponding hole on a furniture base, but several other attachment means for feet are well known in the furniture arts. Applicant does not intend to be limited to this one attachment means. 

I claim:
 1. A sofa kit comprising a first portion, a second portion, a third portion, and a wrench; said first portion having a first portion box which is substantially flat, a first portion base, a first portion main back, a first portion secondary back, a plurality of first portion feet, a plurality of first portion metal threaded rods, a plurality of first portion nuts, and a plurality of first portion washers; said second portion having a second portion box which is substantially flat, a second portion base, a second portion main back, a second portion secondary back, a plurality of second portion feet, a plurality of second portion metal threaded rods, a plurality of second portion nuts, and a plurality of second portion washers; said third portion having a third portion box which is substantially flat, a third portion base, a plurality of third portion feet, a plurality of third portion metal threaded rods, a plurality of third portion nuts, and a plurality of third portion washers; said first portion metal threaded rods are adapted to mate with said first portion main back, said first portion secondary back, said first portion washers and said first portion nuts; said first portion metal threaded rods are adapted to fit through first holes in said first portion base so that when said first portion metal threaded rods are mated to said first portion main back and said first portion secondary back they then fit through corresponding said first holes, said first portion washers and said first portion nuts can then be mated with said first portion metal threaded rods on the distal end of said first portion metal threaded rods from where they are mated with said first portion main back and said first portion secondary back so said first portion main back and said first portion secondary back are attached to said first portion base; said second portion metal threaded rods are adapted to mate with said second portion main back, said second portion secondary back, said second portion washers and said second portion nuts; said second portion metal threaded rods are adapted to fit through second holes in said second portion base so that when said second portion metal threaded rods are mated to said second portion main back and said second portion secondary back they then fit through corresponding said second holes, said second portion washers and said second portion nuts can then be mated with said second portion metal threaded rods on the distal end of said second portion metal threaded rods from where they are mated with said second portion main back and said second portion secondary back so said second portion main back and said second portion secondary back are attached to said second portion base; said first portion feet adapted to attach to said first portion base at a side distal to said first portion main back, said second portion feet adapted to attach to said second portion base at a side distal to said second portion main back, and said third portion feet adapted to attach to said third portion base; said first portion adapted when disassembled to fit inside said first portion box; said second portion adapted when disassembled to fit inside said second portion box; said wrench adapted to fit inside a selection selected from the group comprising said first portion box and said second portion box; and said third portion adapted when disassembled to fit inside said third portion box.
 2. A sofa kit comprising: a plurality of metal threaded rods, a plurality of nuts, a plurality of washers, a plurality of feet having attachment means, a chaise lounge base, a chaise lounge back, a chaise lounge side, a sofa base, a sofa back, a sofa side, a wrench, and an ottoman base; said wrench is adapted to fit said plurality of nuts; said ottoman base adapted to receive said attachment means at a plurality of foot receptacles; said sofa base adapted to receive said attachment means at a plurality of basal receptacles; said chaise lounge base adapted to receive said attachment means at a plurality of perimeter receptacles; said plurality of metal threaded rods are adapted to mate with said plurality of washers and said plurality of nuts; said plurality of metal threaded rods are adapted to mate with holes located on each of said chaise lounge back, chaise lounge side, sofa back, and sofa side and said plurality of metal threaded rods are further adapted to fit through corresponding bores located on said chaise lounge base and said sofa base; and the diameter of said washers is greater than the diameter of said bores. 